ABB ACS800-04 - Hardware Manual

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ABB INDUSTRIAL DRIVES

ACS800-04/-04M (45 to 560 kW)

ACS800-U4 (60 to 600 hp)

drive modules

Hardware manual

Main Page

Table of Contents5
Safety Instructions11
What this Chapter Contains11
Use of Warnings and Notes11
Installation and Maintenance Work12
Grounding13
Mechanical Installation and Maintenance14
Printed Circuit Boards14
Fiber-Optic Cables15
Operation15
Permanent Magnet Motor16
Installation and Maintenance Work16
Start-Up and Operation16
Introduction to this Manual17
What this Chapter Contains17
Target Audience17
Categorization According to the Frame Size17
Categorization According to the Plus Code18
Contents18
Installation, Commissioning and Operating Flowchart19
Terms and Abbreviations21
Operation Principle and Hardware Description23
What this Chapter Contains23
ACS800-04/U4 Product Overview24
ACS800-04M Product Overview25
Example Configurations25
Type Designation Label26
Type Code27
Main Circuit and Control Interfaces29
Diagram29
Operation29
Printed Circuit Boards30
Motor Control30
Connections of the RDCU Control Unit31
Mechanical Installation33
What this Chapter Contains33
Unpacking the Unit33
Before Installation34
Delivery Check34
Requirements for the Installation Site34
Cooling Air Flow35
Cable Channel in the Floor below the Cabinet35
Attaching the Cabinet to the Floor and Wall35
Electric Welding35
Planning the Electrical Installation37
What this Chapter Contains37
Motor Selection and Compatibility38
Protecting the Motor Insulation and Bearings39
Requirements Table40
Permanent Magnet Motor44
Supply Connection45
Disconnecting Device45
Fuses45
Main Contactor45
Thermal Overload and Short-Circuit Protection46
Thermal Overload Protection of the Drive and the Input and Motor Cables46
Thermal Overload Protection of the Motor46
Sensors46
Protecting the Motor and Motor Cable in Short Circuits47
Protection against Short Circuits in the Drive or Supply Cable47
Ground Fault Protection48
Emergency Stop Devices48
Restarting after an Emergency Stop48
Power-Loss Ride-Through Function48
Prevention of Unexpected Start-Up (Option +Q950)49
Terminal for the User Connection50
Safe Torque off (Option +Q967)51
Terminal for the User Connection53
Selecting the Power Cables54
Alternative Power Cable Types55
Motor Cable Shield55
Additional US Requirements56
Conduit56
Armored Cable / Shielded Power Cable56
Power Factor Compensation Capacitors57
Equipment Connected to the Motor Cable57
Installation of Safety Switches, Contactors, Connection Boxes, Etc57
Bypass Connection57
Using a Contactor between the Drive and the Motor58
Tive Loads59
Selecting the Control Cables60
Relay Cable60
Control Panel Cable60
Connection of a Motor Temperature Sensor to the Drive I/O61
Installation Sites above 2000 Metres (6562 Feet)61
Routing the Cables62
Control Cable Ducts62
Electrical Installation63
What this Chapter Contains63
Checking the Insulation of the Assembly63
Drive63
Supply Cable63
Motor and Motor Cable64
IT (Ungrounded) Systems64
Installation of Optional EMC Filter (+E202)64
Example Wiring Diagram65
Power Cable Connection Diagram66
Grounding of the Cable Shields67
Fastening US Cable Lugs68
Example Mounting68
Connections of the RDCU69
Connecting the Control Cables to the RMIO Board70
Connecting the Shield Wires at the RMIO Board70
Securing the Control Cables Mechanically70
Settings of the Cooling Fan Transformer71
Installation of Optional Modules71
Cabling of I/O and Fieldbus Modules71
Pulse Encoder Module Cabling72
Fiber-Optic Link72
Warning Sticker72
Removing the Protective Covering from the Drive Module Air Outlet73
Motor Control and I/O Board (RMIO)75
What this Chapter Contains75
Note on Terminal Labelling75
Note on External Power Supply76
Parameter Settings76
External Control Connections (Non-US)77
External Control Connections (US)78
RMIO Board Specifications79
Analogue Inputs79
Constant Voltage Output79
Auxiliary Power Output79
Analogue Outputs79
Digital Inputs79
Relay Outputs80
DDCS Fiber-Optic Link80
DC Power Input80
Installation Checklist83
What this Chapter Contains83
Checklist83
Start-Up and Use85
What this Chapter Contains85
Start-Up Procedure86
Control Panel87
Removing the Control Panel87
Maintenance89
What this Chapter Contains89
Safety89
Maintenance Intervals90
Layout91
Heatsink92
Fan92
Replacing the Fan (R7)93
Replacing the Fan (R8)94
Capacitors95
Reforming95
Replacing the Capacitor Pack (R7)95
Replacing the Capacitor Pack (R8)96
Replacing the Drive Module97
Leds98
Technical Data99
What this Chapter Contains99
IEC Data99
Ratings99
Symbols101
Sizing102
Derating102
Temperature Derating102
Altitude Derating102
Fuses103
Calculation Example104
Fuse Tables105
Gg Fuses105
Ultrarapid (Ar) Fuses107
Quick Guide for Selecting between Gg and Ar Fuses109
Cable Types111
Cable Entries112
Dimensions, Weights and Noise112
Package Dimensions and Weights113
NEMA Data114
Ratings114
Symbols115
Sizing115
Derating115
Fuses116
UL Class T and L Fuses116
Cable Types118
Cable Entries119
Dimensions, Weights and Noise119
Package Dimensions and Weights119
Input Power Connection120
Motor Connection120
Efficiency121
Energy Efficiency Data (Ecodesign)121
Cooling121
Degrees of Protection121
Prevention of Unexpected Start-Up (+Q950): AGPS-21 Board121
Safe Torque off (+Q967): ASTO-21 Board122
Ambient Conditions122
Materials123
Applicable Standards124
CE Marking125
Compliance with the European Low Voltage Directive125
Compliance with the European EMC Directive125
Compliance with the European Machinery Directive125
Compliance with en 61800-3:2004125
Definitions125
First Environment (Drive of Category C2)126
Second Environment (Drive of Category C3)126
Second Environment (Drive of Category C4)127
C-Tick" Marking127
UL/CSA Markings128
UL Checklist128
Disclaimer128
Cybersecurity Disclaimer128
Resistor Braking131
What this Chapter Contains131
Availability of Brake Choppers and Resistors for the ACS800131
How to Select the Correct Drive/Chopper/Resistor Combination132
Optional Brake Chopper and Resistor(S) for the ACS800-04/04M/U4133
Resistor Installation and Wiring136
Protection of Frame Sizes R7 and R8136
Brake Circuit Commissioning137
Non-ABB Du/Dt Filter Selection139
What this Chapter Contains139
When a Du/Dt Filter Must be Used139
Filter and Installation Requirements139
RDCO-01/02/03/04 DDCS Communication Option Modules141
What this Chapter Contains141
Overview141
Delivery Check142
Module Layout142
Installation143
Installation Procedure143
Technical Data144

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